Modular Compressor Cooling Unit, Appliance, and Method Therefore

Abstract

Present embodiments relate to an appliance. More specifically, but without limitation, the present embodiments relate to a modular compressor cooling unit for a kitchen appliance, and a method therefore which allows a single cabinet to be utilized for two types of appliance cooling systems.

Description

CLAIM TO PRIORITY

This non-provisional patent application claims priority to and benefit of, under 35 U.S.C. § 119(e), U.S. Provisional Patent Application Ser. No. 63/061,462, filed Aug. 5, 2020 and titled “Modular Compressor Cooling Unit, Appliance, and Method Therefore”, all of which is incorporated by reference herein.

BACKGROUND

1. Field of the Invention

Present embodiments relate to an appliance. More specifically, but without limitation, the present embodiments relate to a modular compressor cooling unit for a kitchen appliance, and a method therefore, which allows a single cabinet to be utilized with two types of appliance cooling systems.

2. Description of the Related Art

Prior art appliance cabinets, for example refrigerators and/or freezers typically utilize either an absorption cooling system or a compression type cooling system. The complexity of these assemblies precludes the use of a single cabinet to be used with both types of cooling systems. Instead, present assembly lines typically utilize a dedicated cabinet for the absorption system and an alternate dedicated cabinet for the compression type cooling system. This adds a significant cost to the manufacturing process and additionally adds costs for storage of two separate cabinet systems for parts.

It would be desirable to provide a cabinet which may be utilized with both absorption type and compression type cooling systems.

It would also be desirable to provide a compression cooling system which is usable with the cabinet so that the compression system may be utilized with such cabinet without effecting the structure, function, and operation of the absorption system and which still achieves the desired goals of use of an effective compression type cooling system for the appliance.

It would be desirable to overcome these and other deficiencies in the area of cooling appliances and manufacturing of same to provide an improved device and method of manufacturing.

The information included in this Background section of the specification, including any references cited herein and any description or discussion thereof, is included for technical reference purposes only and is not to be regarded subject matter by which the scope of the invention is to be bound.

SUMMARY

Present embodiments provide a modular compression cooling system which may be provided on a cabinet that is also compatible with an absorption type cooling system. The compression system allows for improved manufacturing and reduction of the number of parts by allowing use of a single cabinet for both types of cooling systems rather than requiring two differing cabinets to accommodate each individual system. This simplifies the manufacturing process.

According to some embodiments, a cooling appliance comprises a cabinet having a plurality of sides and defining an interior space for cooling of food, an opening in a rear surface of the cabinet, a molded duct sized to fit within the opening, the plug capable of being disposed within the opening, an airflow pathway formed integrally through the molded duct, at least one cooling mechanical connected to the molded duct, wherein the cabinet is capable of use with both of a compression cooling system and an absorption cooling system.

According to some optional embodiments, the following features and options may be used with the cooling appliance either alone or in combination with other options. The cooling appliance may further comprise an opening on a forward-facing side of the cabinet, and may comprise at least one door for access to the interior space. The at least one door may be two doors. The molded duct may be formed of a foam material. For example, the foam material may be a polyurethane foam. The molded duct may further comprise a drain. The at least one cooling mechanical may comprise an evaporator. The airflow pathway may comprise a first airflow pathway and a second airflow pathway. The cabinet may have a fresh food compartment and a freezer compartment. One of the first and second airflow pathways corresponding to the fresh food compartment and the other of the first and second airflow pathways corresponding to the freezer compartment. The at least one cooling mechanical serves both of the fresh food compartment and the freezer compartment.

According to some embodiments, a plug for a cooling appliance may comprise a foam body having a shape capable of fitting in an aperture of a cabinet of an appliance, at least one airflow pathway molded integrally in the foam body, at least one edge of the foam body being tapered for an interference fit, a cooling mechanical disposed on the foam body for interaction with airflow moving through the at least one airflow pathway.

According to some optional embodiments, the following features and options may be used with the cooling appliance either alone or in combination with other options. The plug may further comprise a cut-out portion sized to receive at least a portion of an air exchanger. The cut-out portion may have angled surfaces to move condensation to a drain formed in the foam body.

According to a further embodiment, a method of forming an appliance may comprise providing a cabinet for the appliance, forming an opening in a rear area of the cabinet, providing a plug defining an airflow ducting integrally formed in a molded duct and at least one cooling mechanical for the appliance, wherein the molded duct comprises either a compression system cooling mechanical or an absorption system cooling mechanical, and wherein the cabinet is capable of being used with both absorption and compression cooling systems, and, positioning the molded duct in the opening to provide cooling function for an interior of the cabinet.

According to some optional embodiments, the following features and options may be used with the method either alone or in combination with other options. The method may further comprise forming a fresh food portion and a freezer portion in the cabinet. The method may further comprise servicing both of the fresh food portion and the freezer portion with the at least one cooling mechanical.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. All of the above outlined features are to be understood as exemplary only and many more features and objectives of the various embodiments may be gleaned from the disclosure herein. Therefore, no limiting interpretation of this summary is to be understood without further reading of the entire specification, claims and drawings, included herewith. A more extensive presentation of features, details, utilities, and advantages of the present invention is provided in the following written description of various embodiments of the invention, illustrated in the accompanying drawings, and defined in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the embodiments may be better understood, embodiments of a modular compressor cooling unit, appliance, and method therefore will now be described by way of examples. These embodiments are not to limit the scope of the claims as other embodiments of a modular compressor cooling unit will become apparent to one having ordinary skill in the art upon reading the instant description. Non-limiting examples of the present embodiments are shown in figures wherein:

FIG. 1 is a perspective view of an appliance, for example, a refrigerator;

FIG. 2 is a front perspective view of an example appliance with the doors removed;

FIG. 3 is a rear perspective view of the example appliance having the modular compressor cooling unit shown on the rear of the appliance;

FIG. 4 is an exploded perspective rear view of the appliance and the cooling unit;

FIG. 5 is a perspective view of the modular compressor cooling unit;

FIG. 6 is a side view of the modular compressor cooling unit;

FIG. 7 is a side section view of the modular compressor cooling unit;

FIG. 8 is an exploded perspective view of the modular compressor cooling unit,

FIG. 9 is a side section view of the assembled appliance and modular compressor cooling unit;

FIG. 10 is a sectioned perspective view of the appliance with the modular compressor cooling unit mounted to the rear;

FIG. 11 is an alternate perspective view of the modular compressor cooling unit;

FIG. 12 is a front perspective view of an absorption cooling system; and,

FIG. 13 is a rear perspective view of the absorption cooling system of FIG. 12.

DETAILED DESCRIPTION

It is to be understood that a modular compressor cooling unit, appliance, and method therefore are not limited in application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The described embodiments are capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

Reference throughout this specification to “one embodiment”, “some embodiments” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in some embodiments” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

Referring in detail to the figures, wherein like numerals indicate like elements throughout several views, there are shown in FIGS. 1-13 various embodiments of a modular compressor cooling unit, appliance, and method therefore. In some embodiments, the appliance includes a housing and cabinet which comprises an absorption compression system or the modular compressor unit. Additionally, the modular compressor cooling unit may be constructed for easy connection to the housing or cabinet so that either type of cooling system may be selected and chosen during the manufacturing process without the need the for distinct, separate housing for each of the two types of cooling systems. Further, the method comprises steps related to construction of the appliance utilizing either of the two types of cooling systems discussed regardless of the housing type.

Referring now to FIG. 1, a front perspective view of an example appliance 10 is depicted. The example appliance 10 may be a refrigerator, freezer, combination, or other device which is utilized to cool and store fresh or frozen goods and which may utilize an absorption cooling system or a compression cooling system. Although the term “refrigerator” is utilized throughout this specification, the appliance should not be limited to a refrigerator specifically as other appliances may be utilized and implemented in standalone fashion or in combination with other structures or appliances. The refrigerator comprises a housing 12 having a first side wall 14 (FIG. 2), a second side wall 16, and a top 18. The housing 12 may also comprise a bottom 19 and a rear side wall 17 (FIG. 3) to define an enclosure. The housing 12 may comprise at least one cabinet therein.

Along the front of the cabinet is a door 13. Within the housing 12 is a cabinet 20 (FIG. 2) comprising one or more compartments. In some embodiments, there may be a door for each compartment. For example, in the instant embodiment, there is a compartment for fresh food and a compartment for frozen food. Therefore, two doors are shown. In some embodiment, two doors may be used for the fresh food compartment and a door or drawer for the frozen food section. In still other embodiments, French or double doors (side-by-side) may be used to close the upper compartment. Various numbers and combinations may be used depending on the arrangement of compartments. Still further, it is contemplated that a slide drawer may also be utilized to cooperate with the cabinet, alternatively to a door.

The door 13 comprises a hinge (not shown) on one side of the cabinet 20 and housing 12. The hinge may be on the right side or the left side of the cabinet 20 and housing 12. The hinge structure may be internal or external to the cabinet 20. The door 13 may be of the type that allows for reversal of the hinge to work change the opening direction of the door 13, for different kitchen layouts.

Referring now to FIG. 2, the appliance 10 is depicted in an open position by way of removal of the one or more doors 13. In the example embodiment, the appliance 10 includes a first compartment 22 which may be used, for example, as a fresh food compartment, and a second compartment 24 which may be utilized, for example, as a frozen food compartment. In this view, the cabinet 20 is shown divided into the two compartments by a divider 26 which extends horizontally and separates the two compartments so that the first or fresh food compartment is separated from the second or frozen food compartment. While two compartments are shown, one skilled in the art should recognize that various number of compartment(s) may be utilized and still be within the scope of the present embodiments.

The front view also shows the compartments 22, 24 each have rear covers. The first compartment 22 includes a fresh food cover 27 which may allow for air flow and illumination, if desirable. The second compartment 24 may also comprise a cover 28, for example a frozen food cover. Both covers 27, 28 allow for airflow there through and air flow communication with an evaporator in the rear of the appliance 10.

Referring now to FIG. 3, the appliance 10 is rotated into a rear perspective view. From this perspective, the modular compressor cooling unit 30 is shown mounted on the rear side 17 of the housing 12. The modular compressor cooling unit 30 may be connected to the housing 12, as shown, or may be connected to the cabinet 20 on the interior of the housing 12 or may be connected to the housing 12 and the cabinet 20 both. The unit 30 may be connected permanently or removably, for example with fasteners. Any of these variations is within the scope of the present teaching. The modular compressor cooling unit 30 may be installed during the manufacturing process and along the same manufacturing line as an appliance having the alternative cooling absorption system. The modularity of the compressor cooling unit 30 allows that the unit may be connected to the appliance 10 as an alternative to the absorption system while still using the same housing that is used with the absorption system. Thus, a determination may be made in real time, during the manufacturing process, that a compression system is needed, for example as an alternative to a standard absorption system, and the modular compressor cooling unit 30 may be installed in place of such absorption system for any desired number of appliances. The system allows for ease of manufacturing, improved real time decision making during manufacturing based on forecasted needs, or based on orders placed.

Referring now to FIG. 4, the appliance 10 is shown again in a rear perspective view and the modular compressor cooling unit 30 is shown exploded from the appliance housing 12 and cabinet therein.

With the modular compressor cooling unit 30 exploded, a cooling opening 15 is shown in the rear of the housing 12 and into the cabinet 20. The opening 15 provides a place for positioning of the absorption cooling systems, but also allows for positioning of a molded duct 40 for evaporator cooling and the modular compressor cooling unit 30. The molded duct 40 may function like a plug in the opening 15. The cooling opening 15 is typically utilized as a space to house the absorption cooling components of a generally known as absorption cooling appliance. However, with the absorption system removed from the appliance, the cooling opening 15 may be utilized as an area to position ventilation components of the compressor system of the modular compressor cooling unit 30 which allows use of the same appliance housing 12 with either type of cooling system, that is absorption or compressor type. In the rear of the cabinet, within the cooling opening 15, a fan 25 is also shown. The fan 25 may be utilized to move air within the cooling opening 15 to the interior of the cabinet 20 and the first and second compartments 22, 24. The fan 25 may be in flow communication with either or both compartments 22, 24. The modular compressor cooling unit 30 allows a single cooling system to cool two separate or divided compartments which is more desirable than having separate cooling systems for each compartment. In some embodiments, a plurality of fans may be utilized, or multiple cooling systems may be utilized. However, according to the instant example, a single fan 25 may be utilized, and as will be discussed further, splits a single air flow of conditioned air into the freezer and fresh food areas. After exchanging heat in those compartments 22, 24, the air flows are combined again and pulled through the evaporator 44 (FIG. 5) to again condition the air flow. Additionally, depending on the arrangement of compartments within the cabinet 20 an additional optional fan may be utilized as a booster to provide improved air flow to the compartment furthest from the fan 25. Further, while a fan 25 or multiple fans are described, it should be understood that some embodiments may be provided which do not utilize a fan, but instead may include natural draft to move air through the evaporators and compartments.

The modular compressor cooling unit 30 comprises a frame 32 which is attached to the housing 12. The frame 32 includes a plurality of structural members 34 defining the frame 32 and a pan 37 where upon a plurality of compression system cooling mechanicals 36 may be located. For example, a compressor 38, motor (not shown), condenser 41, and the like may be located on the pan 37. These and other cooling mechanicals may be utilized and would be understood by one skilled in the art as they may vary on the exact type of compression activity occurring. Accordingly, the list of cooling mechanicals 36 should not be considered exhaustive as others may be utilized. Further, while the depicted embodiment shows the pan 37 and cooling mechanicals 36 located at the bottom of the appliance 10, it should be understood that the pan 37 and cooling mechanicals may be moved to a different location of the appliance 10. For example, the cooling mechanicals 36 may be mid—way up the appliance 10 so that the modular compressor cooling unit 30 is of a smaller size. This may improve packing and shipping of the modular compressor cooling unit 30 to a manufacturing location of the appliance 10.

The frame members 34 may be formed of various cross-sectional shapes and according to some embodiments may be formed of angle iron structural shapes. The two-leg shape allows one leg for connection to the housing 12 and an alternate leg for connection to the other structural members 34. Various shapes may be utilized. The frame 32 may also include straps or structural members 35 which support the molded duct portion of the modular compressor cooling unit 30.

Disposed within the frame 32 and between the structural members 35 is the molded duct 40, which provides guided airflow through the appliance in structure that can be easily manufactured and inserted as a replacement to an absorption refrigeration system. In some optional embodiments, a rear cover 39 may be utilized to provide a vapor barrier or liner which may also provide an improved aesthetic appearance wherein a molded duct 40 is positioned. The molded duct 40 allows shared use of the evaporator 44 to create two cooling airflows, one air flow for the first fresh food compartment 22 and the second air flow for the freezer compartment 24.

The figure also depicts a rear surface of a duct insert 29. The duct insert 29 engages the molded duct 40 to form ducts or pathways. For example, on the rear side of the depicted duct insert 29, the return air may move from the appliance compartment toward molded duct and a heat exchanger 44 (FIG. 5) therein. On the opposite side of the duct insert 29, the supply air to the compartments may move. In some embodiments, the molded duct 40 and duct insert may be formed as two separate parts and joined by fasteners, adhesives, press/interference fit, or other manufacturing methods. However, in other embodiments the two parts may be formed as a single part.

Additionally, while the molded duct 40 is shown filling the opening 15 which is for only a portion of the rear of the cabinet 20, the molded duct or plug 40 may also be formed to cover an opening extending over the entire rear of the housing 12, or a size that is larger or smaller than the non-limiting embodiment depicted.

Referring now to FIG. 5, the opposite side of the modular compressor cooling unit 30 is shown. The view is taken from the front side of the modular compressor cooling unit 30 which plugs the opening 15 the rear side 17 of the appliance housing 12. Between the frame 32 is the molded duct 40 with a central opening 42. The “term” duct is used generically but should not be considered limiting as the molded duct 40 may define one or more ducts for one or more airflows through the appliance 10 (FIG. 1). The molded duct 40 may be formed of various materials which are, or become, rigid. In some embodiments, the molded duct 40 may be formed of polyurethane foam. Within this central opening 42 is a heat exchanger 44, for example an evaporator, which is utilized to cool the first and second compartments 22, 24 of the appliance 10 when the modular compressor cooling unit 30 is utilized. The heat exchanger 44 is in fluid communication with the cooling mechanicals 36 on the pan 37.

At the lower end of the frame 32, the pan 37 is shown from an alternate view depicting the compressor 38 and other cooling mechanicals 36, for example, the condenser 41 which is fluidly connected to the evaporator 44 by conduit which is removed for clarity.

The frame 32 and remainder of the components shown are positioned against the rear of the appliance as shown in FIG. 4, so that the fan 25 (FIG. 4) is positioned in close proximity to the upper end of the heat exchanger 44. The molded duct 40 provides for guided air flow to the first and second compartments 22, 24 that are separated by the divider 26. Thus, air flow may be established by fan 25 (FIG. 4) and utilize a single heat exchanger 44 rather than requiring two heat exchangers, for example one for each compartment. The molded duct 40 may be formed of polyurethane foam, for non-limiting example. The molded duct may be formed of any moldable, formable, or machinable insulating material or media may be utilized to define this structure. The material should be capable of performing as a plug and withstanding forces associated with the plugging function of some embodiments. A secondary seal material, including a sealant adhesive for example, may be utilized to improve the sealed nature of the plug defined by the molded duct 40. In some embodiments, the molded duct 40 may be formed of the same material as the cabinet 20, so that the materials match and engage one another in an interference manner when the modular compressor cooling unit 30 is utilized.

In the orientation depicted, the air flow is shown represented by the large cross-hatched arrows. The airflow at the top of the heat exchanger 44 is shown with a single cross-hatch and is a supply air to the compartments 22, 24. The air flow returns from the compartments 22, 24 along the front side (the depicted side) of the heat exchanger 44. Upon returning from the compartments 22, 24 the double cross-hatch arrows are shown moving downwardly at an angle returning from the freezer compartment, for example. The return flow from the fresh food compartment joins the return air from the freezer compartment and turns rearward and upward beneath the heat exchanger 44, as shown with the single double-crosshatched arrow. The airflow moves upward through the heat exchanger 44. At or near the top of the heat exchanger 44, the air flow is pulled by the fan 25 (FIG. 4) and is pushed into the compartments 22, 24 by splitting the air flow so that some of the airflow moves toward the lower fresh food compartment.

The molded duct 40 allows the ability to separate supply airflows between the frozen food and fresh food compartments 24, 22. Additionally, the supply air should be separated from the return air. The molded duct 40 in combination with the duct insert 29 separate the supply from the return air.

Referring now to FIG. 6, a side view of the modular compressor cooling unit 30 is shown. On the left-hand side of the modular compressor cooling unit 30, the rear cover 39 is shown adjacent to the frame 32 and the pan 37 is shown at the lower end of the frame 32, extending in the left-hand direction, in the orientation of the drawing. To the right-hand side of the frame 32, the molded duct 40 is depicted. The optional rear cover 39 may cover a portion of the molded duct 40 so that the rearwardly facing surface and portions of the molded duct 40 are not visible to the end user.

In this view, the upper edges of the molded duct 40 are shown as tapered. More specifically, the edges of the molded duct 40 that face the opening 15 (FIG. 4) of the housing 12 (FIG. 4) are tapered inwardly, to engage the opening 15 and plug the opening as the modular compressor cooling unit 30 is installed. In this way, the molded duct 40 may form an interference fit with the edge of opening 15 (FIG. 4). This provides a sealing fit with the remainder of the appliance 10.

Referring now to FIG. 7, a side section view of the modular compressor cooling unit 30 of FIG. 6 is depicted. In this view, the section cut is made through the molded duct 40. Within the interior of this duct area, the heat exchanger 44, for example an evaporator, is depicted having a plurality of coils 45 extending there through.

Below the heat exchanger is an air flow duct 43 which allows movement of the air into one of the compartments 22, 24 of the appliance 10. Additionally, shown at the lower end of the section cut is a drain conduit 46 which will gather and move condensation from within the molded duct 40 and outwardly through the duct and/or the rear cover 39. The drain conduit 46 may be directed to deposit any condensation on the pan 37 below.

Referring now to FIG. 8, an exploded perspective view of the modular compressor cooling unit 30 is shown. At the far-left hand side of the figure, an optional front cover 50 is shown that may or may not be used. The front cover 50 may function as a liner and/or vapor barrier which is positioned over the front surface of the molded duct 40. The front cover 50 is molded in shape similar to the molded duct 40 and, if used, is sandwiched or captured between the heat exchanger 44 and the molded duct 40. The front cover 50 may comprise a similar shape and allow for air flow communication with the interior of the appliance 10. The front cover 50 will also provide a more aesthetically pleasing view for a user who opens the appliance 10 and may see the rear of the appliance 10 and the front cover 50 extending therethrough. The front cover 50 may also cooperate with the molded duct 40 to allow air flow through these molded duct areas to provide the cooling to each of the compartments 22, 24 in use with the heat exchanger 44. The front cover 50 may also act as a vapor barrier between the molded duct and the heat exchanger.

Regardless of whether, the front cover 50 is used, the heat exchanger 44 is shown and is connected directly to the molded duct 40 or to the optional front cover 50, if used. The molded duct 40 is next shown exploded from the frame 32 and comprising the opening 42. The heat exchanger 44 is shown exploded from the opening 42 but is recessed in this opening 42 area when the modular compressor cooling unit 30 is assembled. At a lower end of the opening 42, the molded duct 40 has an area which receives the drain 47. The drain 47 is defined by a pan 48 and a conduit 46. The pan 48 may have a lip 49 extending around a periphery so as to guide water moving along the surface of the opening and the molded duct, into the pan 48 and drain 47.

Forward of the heat exchanger 44, is the duct insert 29. The duct insert 29 cooperates with the molded duct 40 or the front cover 50, if used, to define a separation of the return air from the compartments 22, 24 and the supply air. The return air moves at lower sides of the frozen food compartment 24 and moves downward to join with return air from the fresh food compartment 22. The combined flow then turns rearward toward the heat exchanger 44. The supply air is provided near an upper center area of the frozen food compartment 24 and moves centrally downward on the compartment side of the duct insert 29 to the fresh food compartment 22. The central air flow provides supply and the lateral areas provide the return air flow.

Referring now to FIG. 9, the modular compressor cooling unit 30 is shown in an assembled condition with the housing 12 of the appliance 10 in a section view. In this view, the opening 15 within the housing 12 is shown having an angled or tapered surface 60. The tapered opening 62 provides for an interference fit connection with the exterior surface of the modular compressor cooling unit 30, and specifically, the rear cover 39 (FIG. 6) or the front cover 50 (FIG. 8), or both. In the section view, the evaporator 44 is also shown, as well as fan structure 25 both of which pull air from the compartment 24 across the heat exchanger 44 or vice versa. The divider 26 is shown separating the first compartment 22 from the second compartment 24 and abutting the inwardly facing surface of the modular compressor cooling unit 30.

With regard to FIG. 10, a section perspective view of the appliance housing 12 and the modular compressor cooling unit 30 are depicted. In this view, the appliance housing 12 is shown partially cut. The fan cover 28 allows for intake of air from the second compartment 24 (return air) into the modular compressor cooling unit 30. The return air moves downward along the front surface of the duct insert 29 and joins with the return air of the fresh food compartment 22 below the divider or mullion 26. The combined airflow moves downward along the front of the heat exchanger 44 and turns rearward to the rear side of the heat exchanger 44. It should also be noted that some of the supply air to the second compartment 24 is also moving downward along the front of the duct insert 29 before passing through the fan cover 28.

The combined return air flow then moves upward through the heat exchanger 44 after turning rearward. The airflow moves up through the heat exchanger to cool. At the top of the heat exchanger 44, the cooled air is pulled by the fan 25 and pushed into the compartment 24. Some amount of the cooled air splits to form a second airflow which is pushed to the compartment 22 for fresh food. The air split may be merely due to the second flow path or may be mechanically split by a damper or other mechanical structure.

Likewise, a second circuit is defined for cooling the first compartment 22 when the cooled air splits and is pushed into the first compartment 22. The cooled air is shown moving along the upper surface of the compartment 22 and exiting laterally through the upper cover 27 through supply registers. The cover 27 also has one or more return registers which pull air into the opening 42 and joins return air from the first compartment 22. These return registers are in flow communication with a separate flow duct within the molded duct 40 to keep the supply and return separated. The combined air flow moves downward past to bottom edge of the heat exchanger 44, as previously described to complete the airflow path. After the air flow moves along the heat exchanger 44 and cools, the air again is recirculated back into the first compartment 22 and the second compartment 24.

One skilled in the art should recognize that a single heat exchanger may be utilized for cooling the two separate compartments and this may desirable, as previously mentioned, because it improves the manufacturing process and improves reliability of the unit by reducing parts which may break or create additional unnecessary complications. However, the embodiments also contemplate that separate evaporators may be used for each of the two compartments 22, 24 and be within the scope of the claims.

One skilled in the art will also realize that the opening 42 of the molded duct 40 defines a plenum. On one side of the plenum (the compartments 22, 24 side), the cooled air flow is provided to the first and second compartments 22, 24 and also returns from the compartments 22, 24. On the rear side of the plenum, the air flow interacts with the heat exchanger as the returning, warmer air is cooled as it moves upwardly along the rear of the heat exchanger 44. The fan 25 directs the air flow for both compartments which requires fewer parts and improves manufacturing.

Further, the use of the molded duct 40 in the form of a plug which engages the rear of the appliance 10 allows for ease of interchangeability at the time of manufacturing. For example, if a majority of appliances are to be absorption refrigerators for example, and an order or a sales forecast dictates that a small number of compression appliances need to be manufactured, the plug style molded duct 40 and compressor cooling unit 30 may be easily installed on short notice without drastic changes to the manufacturing process and set up.

Referring now to FIG. 11, a perspective view of the modular compressor cooling unit 30 is shown removed from the appliance housing 12. In this view the front surface of the fan cover 28 is shown. In this view, the fan cover 28 has a supply register 82 centrally located and return registers 83a , 83b . Behind the registers 83a , 83b are the ducts 84a , 84b which are formed in the duct insert 29. Centrally located in the duct insert 29 is a supply duct 86 which moves supply air down to the supply the fresh food compartment 22 via the fresh food cover 27. The duct insert 29 and cover 27 may cooperate to stop the supply air from mixing with the return air, by stopping the supply airflow. The ducts 84a , 84b direct air down to join with the return air retuning through lower apertures in the fan cover 28. The combined return airflow flows behind the duct insert 29 toward heat exchanger 44 (FIG. 10).

With reference now to FIGS. 12-13, perspective view of an absorption cooling system 130 are shown. In the depicted embodiment, the components of the absorption cooling system 130 are shown, which the modular compression unit 30 may be utilized to replace. With reference first to FIG. 12, the absorption cooling system 130 is shown in a rear perspective view wherein the remainder of housing 12 has been removed. At the lower right-hand side of FIG. 12, a boiler assembly 134 is provided which heats a refrigerant fluid mixture. In some embodiments, the refrigerant fluid may be a mixture of ammonia, water and hydrogen to generate the refrigerant mixture in the absorption cooling system 130 and which moves to an upper heat exchanger 136. The boiler assembly 134 may comprise an electric heater or may comprise a burner which is generally located near the bottom of the absorption cooling system 130 and heats the fluid refrigerant mixture.

At the upper area of the absorption cooling system 130, the boiler 134 is in fluid communication with an upper heat exchanger 136, which in this embodiment functions as a condenser. The upper heat exchanger 136 cools the refrigerant fluid mixture before directing the refrigerant fluid mixture to an evaporator cooling fin pack 140 (FIG. 13). Further, a fan 142 is shown beneath the condenser heat exchanger, to force movement of cooling air. For example, as shown by the double lined arrows, the fan 142 may pull air from an absorber 150 below the upper heat exchanger 136 and the pushing the air upwardly across the condenser 136. The fan 142 may be an optional feature to assist the natural draft cooling and increase cooling capacity.

Beneath the condenser heat exchanger 136 is the evaporator cooling fin pack 140 on the opposite side of the absorption system and better seen in FIG. 13. At least one tube 138 extends from the condenser heat exchanger 136, moves down, and through the rear surface of the absorption cooling system 130 to the fin pack evaporator 140 on the opposite side. In some embodiments, the tube 138 turns 90 degrees to extend through a panel to the cooling fin pack evaporator 140.

The absorption cooling system 130 also compromises an absorber 150 shown comprising a coil of tubing 152 which receives fluid returning from the cooling fin pack evaporator 140. The absorber 150 collects the returning ammonia and water allowing them to recombine. Further, the absorber 150 returns to a ballast 156 at a lower end of the absorber 150. The fluid refrigerant mixture also condenses to return from gas state to a fluid state through the absorber and in the ballast. The ballast 156 is generally cylindrical in shape and hollow and is further in fluid communication with the boiler assembly 134 to complete the circuit for refrigeration. The fluid refrigerant mixture is collected in the ballast 156 and returns to the boiler assembly 134.

Referring now to FIG. 13, a front perspective view of the absorption cooling system is provided. In this view, portions of the absorption cooling system 130 are shown which are disposed within the housing 12. The cooling fin pack evaporator 140 is shown which provides cooling for the interior of the appliance 10. Beneath the evaporator fin pack 140, a tray 144 may be disposed for condensation.

With reference to both FIGS. 12-13, one skilled in the art will realize that the absorption cooling system 130 and the modular compression unit 30 (FIG. 3) both utilize the same, size frame 32 (FIG. 4), 132 to cooperate with the housing 12. Accordingly, the present embodiments allow for use of one appliance housing 12 (FIG. 1) which, for non-limiting example, may be primarily manufacturing absorption system appliances, but may on demand manufacture on the same manufacturing line, compression cooling system appliances. This improves manufacturing capabilities and improves change over for small orders or large orders to an alternative cooling system, with minimal impact on the manufacturing process.

In operation, the fluid mixture is heated in a boiler assembly 134. The heated refrigerant fluid moves upwardly through the boiler vessel, which is in the shape of a column and continues moving upwardly to the upper heat exchanger 136. The upwardly extending fluid conduit may function as a water separator. In other embodiments, the water separator 135 may be straight and/or tortuous and may include turbulators, dimples or other features to cause directional changes and/or turbulence in the fluid flow. Within the separator 135, the water and dissolved ammonia components of the refrigerant fluid are separated from the ammonia vapor and the ammonia vapor continues to pass through the condenser 136. Within the condenser 136, heat is removed from the ammonia vapor to condense the vapor before the now liquid refrigerant passes to the evaporator.

Within the evaporator cooling fin pack 140, the liquid ammonia passes through tubing adjacent to the interior wall of the housing 12 (FIG. 1) and more specifically, adjacent to an inner wall of the at least one compartment 22 (FIG. 2), through the evaporation of ammonia. This cools the fin pack in order that more heat may be absorbed from the interior of the appliance. The evaporator 140 removes heat from the at least one compartment 22 to cool the inside of the refrigerator cabinet 20 (FIG. 2). As the hydrogen and vapor mixture move downwardly through the evaporator, toward the absorber, the mixture of hydrogen and ammonia vapor increases in temperature and ammonia concentration as it gains heat from within the cabinet 20. Ultimately, the now completely gaseous mixture reaches the absorber and the absorber may further include water which is drained from the separator and/or boiler vessel so that the complete fluid mixture returns to the absorber and/or ballast and is further directed to the boiler assembly for boiling by the burner or heater to continue the cycle.

While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the invent of embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms. The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases.

Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures.

The foregoing description of methods and embodiments has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention and all equivalents be defined by the claims appended hereto.

Claims

1. A cooling appliance, comprising:

a cabinet having a plurality of sides and defining an interior space for cooling of food;

an opening in a rear surface of the cabinet;

a molded duct sized to fit within said opening, said molded duct disposed within said opening;

an airflow pathway formed integrally through said molded duct;

at least one cooling mechanical connected to said molded duct;

wherein said cabinet is capable of use with both of a compression cooling system and an absorption cooling system.

2. The cooling appliance of claim 1, further comprising an opening on a forward-facing side of said cabinet, and comprising at least one door for access to the interior space.

3. The cooling appliance of claim 2, said at least one door being two doors.

4. The cooling appliance of claim 1, said molded duct being formed of a foam material.

5. The cooling appliance of claim 4, wherein said foam material is a polyurethane foam.

6. The cooling appliance of claim 5, said molded duct further comprising a drain.

7. The cooling appliance of claim 1, said at least one cooling mechanical comprising an evaporator.

8. The cooling appliance of claim 1, said airflow pathway comprising a first airflow pathway and a second airflow pathway.

9. The cooling appliance of claim 8, said cabinet having a fresh food compartment and a freezer compartment.

10. The cooling appliance of claim 9, one of said first and second airflow pathways corresponding to said fresh food compartment and the other of said first and second airflow pathways corresponding to said freezer compartment.

11. The cooling appliance of claim 9, wherein said at least one cooling mechanical serves both of said fresh food compartment and said freezer compartment.

12. A plug for a cooling appliance, comprising:

a foam body having a shape capable of fitting in an aperture of a cabinet of an appliance;

east one airflow pathway molded integrally in said foam body;

at least one edge of said foam body being tapered for an interference fit;

a cooling mechanical disposed on said foam body for interaction with airflow moving through said at least one airflow pathway.

13. The plug of claim 12, further comprising a cut-out portion sized to receive at least a portion of an air exchanger.

14. The plug of claim 13, said cut-out portion having angled surfaces to move condensation to a drain formed in said foam body.

15. A method of forming an appliance, comprising:

providing a cabinet for said appliance;

forming an opening in a rear area of said cabinet;

providing a plug defining an airflow ducting integrally formed in a molded duct and at least one cooling mechanical for said appliance, wherein the molded duct comprises either a compression system cooling mechanical or an absorption system cooling mechanical, and wherein the cabinet is capable of being used with both absorption and compression cooling systems;

positioning said molded duct in said opening to provide cooling function for an interior of said cabinet.

16. The method of claim 15, forming a fresh food portion and a freezer portion in said cabinet.

17. The method of claim 16, servicing both of said fresh food portion and said freezer portion with said at least one cooling mechanical.